Universal, point-mounting apparatus and method

ABSTRACT

An anchor for lightning protection systems includes a base and pad that extend over a sufficient area and a sufficient bearing length to hold in shear and in tension against the weight, shear force, and moment of cables, points, and other components of a lightning protection systems. A universal point mount includes a head presenting greater cross sectional area and greater contact surface area than any other part of the mounting system. Drilled and tapped to receive a point oriented vertically, the head mounts easily on a horizontal or vertical mounting surface by receiving studs from a cleat plate (mandible) whose teeth capture the cable against a relief slot in the head. Apertures and studs provide rotating arbitrarily to any necessary orientation.

1. RELATED APPLICATIONS

This application: is a continuation in part of U.S. patent applicationSer. No. 13/676,292, filed on Nov. 14, 2012 and entitled NON-PENETRATINGANCHOR SYSTEM AND METHOD, which is incorporated herein by reference inits entirety.

2. FIELD OF THE INVENTION

This invention relates to lightning protection systems and, moreparticularly, to novel systems and methods for mounting and anchoringcables and points thereof.

3. BACKGROUND ART

Lightning arresters are central to power systems. Typical power deliveryand transmission systems involve towers or power poles holding longexpanses of power-carrying cables high above the surface of the earthand across large tract of land. The power delivery systems of the publicutilities create a grid across the country connecting cities, powerplants, substations, generators, dams, and so forth.

Surge arresters or lightning arresters are responsible for drawing thecurrent from lightning into conductors that will conduct the energy toground. Accordingly, they may involve wires and air terminals above thelevel of the power carrier cables. Meanwhile, addition surge protectionmay be provided to assure that no breakdown occurs in the insulatorsthat insulate the main power carrier lines from their towers or polesthat suspend them above the earth.

Buildings have a similar problem. They stand above the earth and tend todraw lightning. Thus, lightning rods date from very early days inAmerica. Basic lightning rod systems of yesteryear involved an airterminal or “point” that was typically fastened to extend above thehighest point of a building. This air terminal or point was connected toa cable that conducted electricity from the point down to ground,literally the surface of the earth.

With modern architecture and modern buildings, the problem has becomemore complex in that multiple air terminals or points may be attached toa building, and a building may not have a single highest location.Often, with false fronts, parapets, and other architectural features, arather large expanse of a building architecture may be located at the“highest” location.

Lightning protection for buildings has progressed according to certainstandards. Typically, cables of a suitable size will be connected,anchored at approximately every three feet along their length, and runfrom point to point, where a “point” indicates an air terminal or alightning “point” as that term is used in the art. Typically, all thepoints on a building will be connected to one another and to a groundingcable that carries any electrical power received from the points down tothe ground.

Nevertheless, interfacing hardware with a building presents a designquestion. For example, buildings may be constructed of wood, masonry,concrete, steel, glass, combinations and so forth. The range ofmaterials and their material properties vary widely. Similarly,lightning protection is not the only consideration in designing abuilding.

Meanwhile, lightning protection may often be provided retroactively.Buildings may already exist, and lightning protection may not have beendesigned into them. By the same token, even when lightning protection iscontemplated during the architectural phase of a building, theattachment scheme of a lightning protection system is a considerationthat must be dealt with in view of the other architectural features ofthe building.

At present, electrical fasteners are connected by any suitable means,which usually involves fastening to a structural portion of thebuilding. Thus, protective covers, plates, caps, sheeting, flashing, orother mechanisms for protecting the upper reaches of a building fromweather may be damaged, penetrated, breached, or otherwise compromisedby the fasteners of a lightning protection system. What is needed is aless invasive lightning protection system.

Specific improvements that may be useful include a universal mountingsystem for lightning or arrester points. The point or rod that literallydraws a lightning strike to a protection system, rather than to theprotected structure, may need to be oriented on a horizontal surface, avertical surface, or some other location. Accordingly, it would be anadvance in the art to provide a universal mounting system that willmount to a suitable bracket or building mounting system, and yet becapable of being oriented to receive a lightning arrester point in avertical orientation. Meanwhile, receiving a cable for carrying currentfrom the point and its corresponding mounting hardware should also beaccommodated such that orienting the mount to receive the point leavesavailable a suitable securement location and hardware for receiving andsecuring the conducting cable.

It has Applicants' experience that conventional mounting hardware issometimes destroyed by a lightning strike because the connections areinsufficiently robust, the contact area is insufficiently extensive, andthe cross sectional area of mounting hardware is too small for propercurrent conduction of the current from a lightning strike. More crosssectional area, greater contact area, and greater mass would bebeneficial in the entire contact path from a point to the conductingcable of a lightning protection system.

BRIEF SUMMARY OF THE INVENTION

In view of the foregoing, in accordance with the invention as embodiedand broadly described herein, a method and apparatus are disclosed inone embodiment of the present invention as including an anchor suitablefor supporting the weight of a cable, a point, or other accessoriesassociated with a lightning arrester system. In certain embodiments, ananchor in accordance with the invention may include a base or plate fromwhich a stud extends. In this embodiment, the base or plate and the studtogether form a mounting system to which to secure a bracket or otherdevice designed to secure a cable, point, or the like.

For example, an adhesive pad or interface pad may be secured to theflat, back side of the plate, opposite the stud on the other side. Thepad may provide differential strain and stress between a portion of thebuilding or a location of the building where the anchor is mounted, andthe material of the base.

Likewise, the material of the pad may be selected to provide shockresistance, sealing, flexibility, impact resistance, adhesion, and areconciliation of differing coefficients of thermal expansion betweenthe material of the building and the base of the anchor secured thereto.

In some embodiments, the stud may be threaded to receive a nut or otherkeeper. Similarly, ratchets, binding slides, keys, pins, and other typesof fasteners may be used to secure brackets to the stud in order toanchor points, cables, or both to the anchor, which in turn secures themto the building.

In certain embodiments, a building may include a parapet, wall, or otherarchitectural feature that acts as the extremum the maximum distanceaway from the ground. Accordingly, this parapet or wall may have aflashing, cap, protection, seal, coating, or the like protecting it fromthe elements. Accordingly, the pad may be provided with a structuraladhesive that secures the pad to the flashing, seal, cover, cap, or thelike of the building. Thus, the anchor need not penetrate the protectionprovided against weather on the building. In certain embodiments, thestud may hold a bracket of any suitable type that will secure a point, astandoff, a bracket, a clip, or other holder suitable for holding acomponent of the lightning protection system.

In yet another embodiment, an integrated or universal anchor may beformed from sheet metal to have arms that extend away from the base orplate a certain distance, cantilevering with respect thereto anddeflecting in a response to force. The arms may extend and be bent orotherwise formed into guides, which may terminate in retainers. Incertain embodiments, the cables may be pushed against the guides, whichact as springs and also push against the arms, such that the guides andarms together deflect away from the cable, thus opening a gap suitablefor receiving the cable against the base. In response to the cablesnapping in past the guides, the arms and guides may return to theirunstressed positions, capturing the cable by a retainer connectedthereto. Thus, the cable may be held permanently, in a very simplesystem that snaps the cable into place.

In one embodiment of a process in accordance with the invention, a usermay select parameters controlling the performance of an anchor, andselect properties of materials and structures. Securements may beselected, after which materials meeting the parameters, properties, andstructures may be selected. Stock may be cut and anchors may beassembled, fabricated or otherwise manufactured.

Providing an instruction for installation procedures and operatingprocedures with a packaging for the anchors, a manufacturer maydistribute the anchors to installers. Installers may then analyzespecifications for their installation, select sizes, materials, andprocesses suitable and apply the anchors to a building. Thereafter, thecables and points may be installed with other ancillary equipment,secured by the anchors.

For example, in one embodiment one may size the anchors in order tominimize the leverage, moment, or couple (engineering terms, used hereas known in the engineering art) to support the weight of cables. Thecables need to be supported not only against their own dead weight, butalso against the weight of pulling or tensioning to which installerswill subject the cables in order to minimize the sag in the cables.

Selecting a pad material may be done at the time of manufacture of ananchor, or may be done at a different time. Typically, pads will besized, cut, and applied to anchors in a manufacturing situation. Thepads will then be applied to a building as part of the anchor. Aninstaller may remove a protective coating, such as a polymer filmattached to an adhesive layer of the pad or on the pad in order toexpose the pad for use. An installer may select a location on abuilding, and may need to clean that location.

For example, dust, debris, oxidized base material, and the like mayinterfere with adhesion. Therefore, a location on a building may becleaned by solvents, scrubbing, wiping, or the like. Removing anyprotective layer will expose the pad such that the anchor can then beapplied.

Applying a cure condition may be required for one of several reasons.For example, polymers may need time, heat, ultraviolet light, or otherchemical effects in order to cure. In certain embodiments, wherematerials are adhesives that do not rely on the chemistry of their basematerial or of the location to which attached, materials may simply needtime in order to fully flow, creep, or otherwise secure to an anchoringlocation. By whatever means required, application of a cure conditionmay be followed by positioning cables, including tensioning them inorder to reduce sag. Thereafter, the cables may be bound to the anchorsby brackets, whether integrated, bolted on, or the like.

Such a system provides many benefits. The load is distributed over amuch larger area by anchors in accordance with the invention. The actualcross sectional area of material from the cover or wall protection towhich an anchor may be secured is substantially larger than that of athreaded-in fastener, which penetrates and engages a small fraction of asquare inch of area of building material. Moreover, there is nopenetrating whatsoever of the seal, cap, flashing, or other protectionmaterials and structures of the building. Thus, capillary action isabsent to damage the building covered by the protection of the cap,seal, or the like.

Moreover, there is no caulking step to put a washer, caulk, putty, orthe like around the area where a penetration has been put through aprotective layer, into a wall, or both. Rather, the pad may form a sealto survive many freeze and thaw cycles. It may be selected of a materialthat will not harden with time, temperature extremes, or the like.

Likewise, there will be no need to set up a system of anchors limited toproceeding along horizontal surfaces at the top of a building. Thereneed be no waiting for a period of days before they will sufficientlycure to hold. If some systems are used on vertical surfaces, they mustbe maintained above a minimum temperature, typically around fiftydegrees Fahrenheit, and maintained for several days, typically two tothree, before they are sufficiently cured to hold. Even then, they mayhave wide spread failures.

In accordance with the invention, non-penetrating, comparatively rapidlymounted, supports may be installed as anchors on vertical surfaces.

In one specific embodiment of an apparatus and method in accordance withthe invention, a head is configured to mount with a correspondingbracket or mandible to be secured on a non-penetrating base plate. Thebase plate, having a square shape, and having four studs projecting fromthe four corners thereof, may receive a cleat plate or mandible that isalso shaped as a square, and which may be oriented with any corneraperture matched to a particular stud of the base plate. In this way,the cleat plate or mandible may be secured in any of four differentorientations to a base plate, and secured thereto on the studs thereof.Meanwhile, two studs oppose 180 degrees from one another project out ofthe face of the cleat plate or mandible. Likewise, along each side isoriented a rack that is cut partially from the mandible and bent awayfrom the base plate to present the teeth toward the head. Thus, all foursides of the mandible have teeth directed toward the head.

The head then includes slots or relief extending as a cross or x alongthe backside thereof. The relief sits over the rack of teeth on eachside and extends across the full diameter of the head. The relief orslot orients and secures a cable between the head and the teeth. Due tothe orientation of the studs of the mandible, and the teeth, a cable maybe run in either direction from side to side across the mandible, andany other direction from side to side across the head. Thus, the headmay be oriented in either two positions to the mandible, and themandible may be positioned in any of four positions, two symmetric pair,with respect to the base plate.

Thus, the mandible may be mounted to the base plate and the head may bemounted to the mandible in such a way that the point may be directedvertically regardless of whether the supporting surface for the baseplate is horizontal or vertical.

Also, the head is comparatively thick, thus having substantial carryingcapacity for electrical current received from the lightning strike. Thisprovides a considerably improved connection from the point to the cable,in which the attachment hardware does not create a current limitinglink. Particularly, the current carrying capacity of the head issufficiently great that it presents always a greater cross sectionalarea than the point, the cable, or the mounting hardware for currentcarrying capacity. Also, the contact area is between the conductor(cable) and the head, as well as between the point and the head. Otherattachment hardware is not in the direct path of conducting a strike.Those attachment devices may still see the capacitive currents that flowas free electrical charge fills all conductors, but they do not carrythe principal current to ground from a strike. The head is alsosufficiently heavy to minimize temperature rise, dissipate resistiveheating, and maintain structural integrity without melting. Arcs arepossible but are preferentially directed by geometry to remain insidethe envelope of the contact regions between the cable strands and thehead, and between the threads of the point and matching threads of thehead.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a non-penetratinganchor for a lightning arrester cable support in accordance with events;

FIG. 2 is a rear perspective view of the anchor of FIG. 1;

FIG. 3 is a front elevation view of the apparatus of FIG. 1;

FIG. 4 is a rear elevation view thereof;

FIG. 5 is a top plan view thereof;

FIG. 6 is a bottom plan view thereof;

FIG. 7 is a left elevation view thereof;

FIG. 8 is a right side elevation view thereof;

FIG. 9 is a frontal perspective view of an alternative embodimentrelying on a circular base plate for the anchor of FIG. 1;

FIG. 10 is a rear perspective view thereof;

FIG. 11 a front elevation view thereof;

FIG. 12 is a rear elevation view thereof;

FIG. 13 is a top plan view thereof;

FIG. 14 is a bottom plan view thereof;

FIG. 15 is a left side elevation view thereof;

FIG. 16 is a right side elevation view thereof;

FIG. 17A is a frontal perspective view of an alternative embodimentrelying on an oval shape for the base plate of the anchor of FIGS. 1 and9;

FIG. 17B is a rear perspective view of the anchor of FIG. 17A;

FIG. 18A is a front elevation view thereof;

FIG. 18B is a rear elevation thereof;

FIG. 18C is a top plan view thereof;

FIG. 18D is a bottom plan view thereof;

FIG. 18E is a left side elevation view thereof;

FIG. 18F is a right side elevation view thereof;

FIG. 19A is a frontal perspective view of an alternative embodimentrelying on a diamond shape for the base plate of the anchor;

FIG. 19B is a rear perspective view thereof;

FIG. 19C is a front elevation view thereof;

FIG. 20 is an exploded view of one embodiment of an anchor in accordancewith the invention, this having two studs rather than a single stud asin FIGS. 1-19, and including an exemplary bracket with fasteners, apoint, and so forth;

FIG. 21 is a partially cut away, exploded view and assembly view of twoembodiments of brackets for anchoring cables with the anchors inaccordance with the invention;

FIG. 22 is a frontal perspective view of an alternative embodiment of auniversal anchor providing quick insertion and retention of cables in ananchor system in accordance with the invention;

FIG. 23A is a front elevation view thereof;

FIG. 23B is a rear elevation view thereof;

FIG. 23C is a top plan view thereof;

FIG. 23D is a bottom plan view thereof;

FIG. 23E is a left side elevation view thereof;

FIG. 23F is a right side elevation view thereof;

FIG. 24 is an exploded view of the anchor of FIG. 22 illustrating thepresence of the securant pad behind the base plate thereof and the cableto be inserted therein;

FIG. 25 is an assembled view of the anchor of FIGS. 22-24, secured to acovering or cap such as a flashing over a wall or parapet at the top ofa building;

FIG. 26A is a frontal perspective view of an alternative embodiment of auniversal anchor, this having an ability to completely cover the frontof the secured cable;

FIG. 26B is a frontal perspective of the embodiment of FIG. 26 a,illustrating a cable, shown in a partially cut away view and retainedtherein;

FIG. 27A is a front elevation view of the embodiment of FIGS. 26A-26B;

FIG. 27B is a rear elevation view thereof;

FIG. 27C is a top plan view thereof;

FIG. 27D is a bottom plan view thereof;

FIG. 27E is a left side elevation view thereof;

FIG. 27F is a right side elevation view thereof;

FIG. 28 is a schematic block diagram of one embodiment of a method formanufacturing and installing anchors in accordance with the invention,such as the anchors of FIGS. 1-27;

FIG. 29 is a schematic block diagram of the details of one alternativeembodiment of a method for using an anchor in accordance with theinvention.

FIG. 30 is a perspective view of the system of FIG. 1 with the pointmounted to extend from a mounting head affixed to a horizontal surfaceof a protected structure; structure;

FIG. 31 is a perspective view of a point anchoring system in accordancewith the invention with the point oriented vertically from a verticalmount on a vertical surface of a protected

FIG. 32 is an exploded view thereof;

FIG. 33 is an upper frontal perspective view of the head in a horizontalorientation;

FIG. 34 is an under side frontal perspective view of the head of FIGS. 1through 3;

FIG. 35 is a top plan view thereof;

FIG. 36 is a bottom plan view thereof;

FIG. 37 is a front elevation view thereof;

FIG. 38 is a rear elevation view thereof;

FIG. 39 is a right side elevation view thereof;

FIG. 40 is a left side elevation view thereof;

FIG. 41 is a perspective view of the cleat plate or mandible of thesystem of FIGS. 1 through 3;

FIG. 42 is a perspective view of the blank for the mandible or cleatplate of FIG. 11;

FIG. 43 is a top plan view of the cleat plate or mandible of FIG. 11;

FIG. 44 is a bottom plan view thereof;

FIG. 45 is a front elevation view thereof, which is identical to therear elevation view, left side elevation view, and right side elevationview thereof;

FIG. 46 is a top plan view of the blank for a cleat plate or mandible ofFIGS. 11 through 15;

FIG. 47 is a front elevation view thereof, which is identical to therear elevation view, left side elevation view, and right side elevationview thereof; and

FIG. 48 is a front elevation view of the cleat plate or mandible ofFIGS. 11 through 17, with the racks and teeth deflected to theiroperational positions, but absent the studs that are installed tocomplete the mandible.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the drawingsherein, could be arranged and designed in a wide variety of differentconfigurations. Thus, the following more detailed description of theembodiments of the system and method of the present invention, asrepresented in the drawings, is not intended to limit the scope of theinvention, as claimed, but is merely representative of variousembodiments of the invention. The illustrated embodiments of theinvention will be best understood by reference to the drawings, whereinlike parts are designated by like numerals throughout.

Referring to FIG. 1, and generally to FIGS. 1-21, an anchor 10 may beformed to have a base plate 12. The base plate 12 will typically besecured to a building in order to support lightning protection cablinginterconnecting several points or rods extending upward to cause a highvoltage stress field around the distal end or tip thereof.

Accordingly, such points are typically formed of rod of a suitablediameter, and having a length of from about 8 to about 24 inches.Accordingly, each of these points tends to cause a stress concentrationfield of voltage potential about the distal end thereof. Thispreferentially causes each of these tips of these points or rods to bethe first items struck by lightning, rather than having other structuralor electrical components of the building take such a risk.

Anchors 10 in accordance with the invention may be distributed aroundwalls, parapets, cupolas, or other extremities of a building. Typically,a ridge line, a parapet around a roof region, or the like may receivethe anchors 10. The anchors 10 will support various fasteners (a term ofart in lightning protection technology), which may be thought of asmechanical brackets, or other securement mechanisms to hold cables, thepoints, and so forth.

The base plate 12 may be fabricated with a stud 16, in a manufacturingprocess similar to that of manufacturing a bolt, a nail, or the like. Inan alternative embodiment, the studs 16 may be attached to the base 12after individual fabrication of each 12, 16.

The base plate 12 may be provided with a pad 14 that operates as a seal,and adhesive mechanism, a thermal expansion attenuator, a strainattenuator, and so forth. That is, between the base plate 12 and acorresponding portion of a building, a differential in coefficience ofthermal expansion may exist. Similarly, temperature variations maychange properties.

Likewise, freezing and thawing may intervene in capillary spaces betweenthe base plate 12 and a building. A freeze-thaw cycle will eventuallyseparate the base plate 12 of the anchor 10 from the building.Accordingly, the pad 14 may be, for example, a closed-cell foam of aparticular type suitable for the task to form a seal. Likewise, the pad14 may be provided with an adhesive material on the opposing surfacesfaces in order to bond to a building and to the base plate 12.

In certain embodiments, the pad 14 has been found to serve well iffabricated of an acrylic expanded foam or expanded acrylic, commonlyknown as a foam. Likewise, various acrylate adhesives have been foundsuitable for rendering the pad 14 pressure sensitive, curable or both inbonding to the base 14.

Referring to FIGS. 1-2, as well as FIGS. 3-19 (including 19A-19C)illustrate various embodiments of an anchor 10. In these embodiments,the stud 16 protrudes at a right angle or perpendicularly with respectto the front face 18 or surface 18 of the base plate 12. Meanwhile, theback face 20 or surface 20 of the plate 12 receives the pad 14. The pad14 is mechanically adhered thereto to support the stress, strain,tension, compression, and shear that may be applied to the pad 14 byloads introduces through the studs 16 to the base 12.

Meanwhile, the face 22 or front face 22 of the pad 14 adheres by way ofan adhesive applied thereon or forming the face 22 thereof. This willbond to the back face 20 of the base plate 12. Similarly, the rear face24 or surface 24 of the pad 14 is also provided with an adhesivequality, whether applied as a separate material, or as an integral partof the pad 14. The face 24 may be covered with a protective layer, notshown, in order to protect the face 24 against debris, and maintain itcompletely clean and operable. Removing the layer exposes the adhesivefor adhering the rear face 24 to a suitable surface in a building.

The studs 16 may include a tip 26 formed as a screw or bolt. Typically,the tip 26 will be slightly tapered, in order to pilot the studs 16 intoa threaded fastener or keeper, such as a nut.

At the opposite end of the studs 16 is the root 28 and or root portion28. The root portion 28 may or may not be threaded. That is, threads 30near the tip 26 may receive a fastener, such as a keeper, nut, or thelike. Meanwhile, if the threads 30 continue all the way to the root 28,then very thin materials may be held snugly against the front face 18 ofthe plate 12 by such fasteners. Nevertheless, in some embodiments, thethreads 30 need not proceed all the way to the root 28 of the studs 16.

Referring to FIGS. 3-19, note that trailing letters indicate drawings orfigures in a set, having some relationship. Thus, herein, the text mayrefer to FIG. 19, to include FIGS. 19A, 19B, 19C, and so forth. FIGS.3-8 illustrate the orthogonal views of the apparatus of FIGS. 1 and 2.FIG. 2 illustrates a partially cut away pad 14 in order to illustratethe back surface 20 of the plate 12. In some embodiments illustratedherein, the pad 14 will be removed, and only the plate 12 and stud 16 ofthe anchor 10 will be illustrated. In other embodiments, orillustrations the pad 14 will be in place. In FIGS. 3-8, the variousorthogonal embodiments illustrate the rectangular, or square plate 12with its associated studs 16.

Referring to FIGS. 9-10, a perspective view from the front and rear ofan alternative embodiment is shown, relying on a circular plate 12. Oneadvantage of a circular plate 12 is that orientation of the plate 12becomes less significant. For example, with a rectangular or otherwisecornered plate 12, orientation will be obvious to the eye of a casualobserver. In contrast, a circular plate 12 is point symmetric and neednot be oriented in a specific manner in order to operate and yet toappear aesthetically pleasing.

Referring to FIGS. 11-16, the various orthogonal views of the embodimentof FIGS. 9-10 look very similar to those of FIGS. 3-8.

Referring to FIGS. 17A-17B, a frontal and rear perspective view of anoval embodiment of a base plate 12 needs to be oriented, but theprecision required of straight lines may not be required. In thisembodiment, the long axis of the elliptical or oval shape will typicallybe oriented vertically in order to provide more leverage advantage bythe base plate 12, and particularly, a pad 14. In this way, the leverageof the studs 16 will be reduced against peeling or tipping the baseplate 12 and pad 14 away from a wall to which it is attached.

Referring to FIGS. 18A-18F, the orthogonal views of the embodiment ofFIGS. 17A-17B are illustrated. Again, these views appear very similar tothose of FIGS. 11-16, with a major and minor axis, rather than a singlediameter.

Referring to FIGS. 19A-19B, a diamond shape may be suitable for oneembodiment of a plate 12 in accordance with the invention. In thisembodiment, the vertical dimension is a maximum, again providingadditional leverage, compared to a square embodiment. Even if the squareembodiment of FIGS. 1-2 were installed in a diamond configuration, themaximum vertical dimension of the installed plate 12 would have about40% more length. This may provide, accordingly, more leverage, and agreater supporting “moment” as that terms is used in engineering.

Referring to FIG. 19C, a front elevation view of the embodiment of FIGS.19A-19B illustrates that the other orthogonal views are unnecessary inorder to have a clear understanding of the shape from each direction.Again, this embodiment militates in favor of a comparatively preciseorientation. This is not so much for mechanical strength, which wouldvery little with a matter of a few degrees of rotation of the plate 12against the surface. Rather, it is valuable for aesthetics, where anyorientation away from vertical would be immediately noticeable to acasual observer.

Referring to FIG. 20, an exploded view of one embodiment of an anchor 10in accordance with the invention illustrates the pad 14 backing the baseplate 12 to which the studs 16 are secured, fabricated, attached, orintegrally manufactured. In this embodiment, a keeper 32, such as a nut32 is used to thread onto the threads 30 of the stud 16. This willsecure a fastener 34 to the plate 12, and thus to the mounting surface35 of a building.

In this embodiment, the studs 16 pass through apertures 36, thus makingthemselves available for receiving the keeper 32 or the nut 32. As eachnut 32 is threaded toward the root 28, beginning at the tip 26 of thestud 16, the fastener 34 is drawn toward the front face 18 of the baseplate 12. In the illustrated embodiment, a stand off 38 extends awayfrom the base plate 12, in order to support a point 40. The point 40 isshown in engineering style with the intermediate length continuing asthe portions illustrated.

In this embodiment, the point 40 may be secured by a securement 42 suchas a set screw 42 threaded into a receiver 44 that mounts the point 40to support it in a vertical orientation. As described hereinabove, thepoint 40 operates to draw lightning, by increasing the voltage stressfield near the distal end thereof (farthest from the building).

Referring to FIG. 21, while continuing to refer generally to FIGS. 1-29,an installation of an anchor 10 in accordance with the invention mayinclude attachment of an anchor 10 by a pad 14 to a surface 35 of abuilding. In the illustrated embodiment, the surface 35 is part of acovered wall 52 or parapet 52. The parapet 52 or wall 52 is simply usedby way of example.

In other embodiments, the surface 35 may be part of a covering on aridge line or ridge cap from a building, a cupola, gable, eave, or otherarchitectural feature that represents a high point in the structure of abuilding. Accordingly, the parapet 52 or wall 52 represents allocationthat permits the point 40 to be the high point of the building byselecting a surface 35 to which the anchor 10 may be installed.

Thus, the installation 50 or assembly 50 may include, for example, ananchor 10 secured by a pad 14 against a surface 35 of a flashing 54 orcap 54 covering a portion of a wall 52.

In the illustrated embodiment, the cap 54 or flashing 54, may include adrip edge 55. The drip edge 55 is instructive. Significant effort istaken to assure protection of the wall 52 against the elements,particularly rain, and the freeze-thaw cycle of winter moisture.Accordingly, the drip edge 54 proceeds away from the wall 52, in orderto assure that water striking the flashing 54 or cap 54 is conductedaway therefrom. This may assure that it drips elsewhere, rather thanfeeding capillary spaces between the wall 52 and the flashing 54.Likewise, the drip edge 55 militates against water dripping directlyfrom the flashing 54 onto the wall 52.

In the illustrated such as the one embodiments, illustrated in FIG. 21,a cable 56 is secured by the anchor 10 to run along the wall 52,attached to the surface 35 of the cap 54 or flashing 54. In the far leftembodiment, as illustrated, the anchor 10 includes a base plate 12.Thus, the anchor 10 a shows an assembled configuration of the anchor 10b also illustrated.

For example, a cable 56 is secured directly against the base plate 12 bytabs 58 that operate as extensions of the base plate 12. Tabs 58 foldover to hold the cable 56 in place. In some embodiments, such a simple,straightforward attachment mechanism may be operable without tools.

With the tabs 58 fully open, and extending as if within the plane of thebase 12, an installer may press the pad 14 against the surface 35 of theflashing 54. This anchoring of the base 12 and pad 14 secures them tothe surface 35 and may be used to secure them to each other. Afterapplying pressure and waiting, or otherwise curing the securement of thepad 14 to the surface 35, an installer may then run the cable across theplate. Cable 56 may be fastened in place by bending the tabs 58 over thecable 56 and plate 12, and specifically over the front face 18 of theplate 12.

In the alternative embodiment of the anchor 10 c, a location 60 may beselected, as shown in the exploded view, for receiving a pad 14 aftersuitable cleaning. Typically, the pad 14 here may be preinstalled on theanchor 10 at a factory, being secured to the base plate 12.Nevertheless, in some embodiments, the pad 14 may be applied in thefield.

By whatever mechanism, the rear face 20 or back face 20 of the baseplate 12 adheres to the pad 14, by being fastened to the front face 22thereof. Meanwhile, the back face 24 of the pad 14, after a suitablecleaning of the surface 35 at the location 60, is adhered to the surface35 at the location 60.

In the embodiments of the anchors 10 c, and 10 d, a stud 16 protrudingfrom the base 12 receives a fastener 36, which fastener 36 actuallyholds the cable 56. In the illustrated embodiment, the fastener 34 isprovided with an aperture 36 to receive the stud 16 therethrough.Accordingly, as illustrated in FIG. 20, a nut 32 or other keeper 32 maysecure to the stud 16, thus capturing the fastener 34, and the cable 56held by the fastener 34 to the base plate 12. Of course otherembodiments of brackets may simply include loops, clamps, and the likesimply supported by the stud 16 and base plate 12.

Referring to FIG. 22, which is detailed in FIGS. 22-25, a universalanchor 10 may provide a clip mechanism for quickly securing a cable 56to a building wall 52. In the illustrated embodiment, the universalanchor 10 includes arms 62 that operate as springs, being able todeflect.

Near the center of the anchor 10, shown here in a vertical orientation,the arms 62 support a horizontal cable captured thereby. The anchor 10may include a guide 64 or guide portion extending from the arm 62. Cablepushed between opposing guides 64, will tend to deflect the guides 64,and the arms 62 as cantilever springs. Upon opening a gap between theguides 64, a cable pressed into the guides 64 will move the guides 64and arms 62 outboard. Moving in an outboard direction opens up a gap toreceive the cable 56.

The retainers 66 will hold a cable 56 in place after the cable passesinto the cable region 68. That is, after passing the guides 64, thecable no longer exerts the outboard pressure on the guides 64. Theguides 64 and arms 62 may again return to their unstressed, unstrainedpositions, locking the cable 56 in place 68.

Typically, the vertex 69 tends to restrict the gap 63, thus requiringthe guides 64 to push the arms 62 as cantilevers. The arms 62, acting ascantilever springs against the base 12, are moved away (outboard) untilthe vertex 69 of each guide 64 passes over a center line or centerdiameter of the cable 56. Thereafter, the retainers 66 tend to ride upon the cable 56, once in the cable region 68, thus drawing the cable inagainst the base plate 12. This occurs as the arms 62 close back overthe cable 56 to their 62 original position. Thus, the retainers 66operate to draw the cable in, against the plate 12 by force of thespring loads presented by the arms 62 and guides 64.

The anchor 10 may be referred to as a combined anchor and bracket 70 ora universal anchor 70. Thus, a particular embodiment of an anchor 10that includes both the base 12 integrated with a mechanism forbracketing, without requiring an extra piece distinct from the base 12as a fastener 34, may be considered a universal or integrated anchor 10.

Referring to Figures to 23A-23F, the various orthogonal views of theembodiment of FIG. 22 illustrate the details and approximate aspectratios or relationships between dimensions. Meanwhile, these orthogonalviews may be seen to present a universal anchor 70 or integrated anchor70 that may be formed by simply cutting and bending a sheet of material.Thus, the material of the integrated bracket 70 or universal bracket 70may typically be metal, although other materials may be suitable. Forexample, certain composite materials, polymeric materials, such ascertain industrial plastics, and the like, may serve as the material forforming a universal bracket 70 as illustrated.

Referring to FIGS. 24-25, while continuing to refer to FIGS. 22-23, andFIGS. 1-29 generally, the integrated bracket 70 of FIG. 22 isillustrated in an exploded view with the pad 14 and cable 56 notsecured. In FIG. 25, the assembly 50 includes the universal bracket 70of FIGS. 22-24 in place, having the cable 56 installed, and the anchor10 or universal anchor 70 installed on the surface 35 of a cover 54 of awall 52. As mentioned hereinabove, the integrated anchor 70 or universalanchor 70 is a particular embodiment of an anchor 10.

Referring to FIGS. 26A-26B, in an alternative embodiment of a universalanchor 70, a base 12 may include arms 62 and guides 64 that are notnecessarily symmetrical with one another. For example, in theillustrated embodiment, the lower arms 62 may be longer, or may be thesame length as the upper arms of 62. Meanwhile, the guides 64 aretypically not symmetrical, and may be shaped differently to fulfilldifferent purposes.

For example, the lower guides 64 operate as guides, tending to bend ordeflect away from a cable 58 inserted between the guides 64. Bending thearms 62 away from the cable 58. The upper arms 62, and the upper guides64 b operate similarly. As cantilever springs, each pull away from ordraws away from the center or unloaded position according to the forceapplied by a cable 58 being forced between the guides 64.

However, unlike previous embodiments, the upper guide 64 terminates in adifferent shape than does the lower guide 64 a. Thus, the lower guide 64a is a continuation or continues on as the retainer 66 a. Meanwhile, thelip 66 b is not so large, and simply provides a transition for the guide64 b. Herein, throughout this text, a trailing letter behind a referencenumeral simply indicates a specific instance of the item identified bythat reference numeral. Thus, a guide 64 is also capable of being aguide 64 a, or guide 64 b. Put another way, a guide 64 a is a specificinstance of a guide 64 generally, and all may be designated as a guide64. Similarly, a guide 64 b is a specific instance of a generic guide64. In similar fashion, the retainer 66 a provides an actual receiver 66a to hold and to completely cover a cable 58 when placed in the cable 56when received in the cable region 68.

As illustrated, the cable 56, when forced toward the base plate 12between the guides 64, tends to drive the guides 64 apart, acting ascantilever springs. Meanwhile, the guides 64, in turn, drive the arms 62apart, also operating as cantilever springs with respect to the base 12.Once the gap 63 between the guides 64 has been traversed, the cable 56may be drawn in by the retainers 66 as they close in together.

The spring force of the guide 64 b pushes the detent 66 toward the cable56. Accordingly, once the cable 56, driven in between the guides 64 a,64 b has sufficient clearance, then the diameter of the cable 56 tendsto drive the guide 64 a upward, as the detent 66 b and the arms 62 drivethe guides 64 b toward the cable 56, and toward the arms 62 a. In thisway, the upper arm 62 b tends to drive the cable 56 into the retainer 66a.

In summary, an installer forces the cable 56 between the guides 64 a, 64b. The guides 64 a, 64 b, acting as springs, deflect, also applying andtransmitting force to their respective arms 62 a, 62 b. The combineddeflection of the guides 64 and the arms 62 opens the gap 63 between theguides 64, thus receiving the cable 56. Upon the passage of the guide 64a over the central diameter or maximum diameter of the cable 56, thecable 56 is seated within the retainer 66 a. Meanwhile, the combinedforces of the guide 64 b pushing the cable into the cable position 68under the retainer 66 a, is augmented by the force of the arms 62 bdriving the guides 64 b and detent 66 b against the cable 56, until thecable 56, is well into the retainer 66 a.

Referring to FIGS. 27A-27F, while continuing to refer to FIGS. 26A-26B,one can see that the integrated anchor 70 provides a cover 66 or aretainer 66 over the outermost surface of the cable 56. Notwithstandingthe embodiment of FIGS. 22-25, which can easily retain the cable 56, theembodiment of FIGS. 26A-27F provides a positive element 66 covering theoutside of the cable 56.

Referring to FIG. 28, a process 80 of using an anchor 10 in accordancewith the invention may include both a manufacturing process 82 and aninstallation process 84. For example, in certain embodiments, the anchor10 may actually be assembled onsite. In other embodiments, the anchormay be completely manufactured, assembled, and simply applied to a wall.

As discussed hereinabove, in certain embodiments brackets 34 may beselected according to a specific need. They may be used to support acable, a point, or a specialty item in a lightning-protection circuit.In certain embodiments of an anchor 10 in accordance with the invention,brackets 34 may be conventional, They may be mounted to support cables,points, or the like on a structure of a building by an anchor 10 inaccordance with the invention. In other embodiments, an integratedanchor 70 may actually include all bracketing and anchoring in a singlepiece, even a monolithic piece 70 of a simple homogeneous material.

By any mode, a method 80 for using anchors 10 in accordance with theinvention may include manufacturing and providing 82, followed by aprocess 84 of installation.

Selecting 85 may involve selecting parameters that will govern theperformance of an anchor 10 in accordance with the invention. Forexample, in certain embodiments, the specific material properties may besignificant. Thus, selecting values corresponding to material propertiesmay be important.

In some embodiments, determining whether a material property requires ametal, a polymer, a composite, or the like may hinge on the specificperformance characteristics in terms of strength, spring constant, yieldvalues of stress, deflection, maximum working strength, stiffness, andso forth.

Based on the parameters that are selected 85, selecting 86 the materialproperties may be done by specifying what values the parameters mustmeet. Thus, operational parameters may result in the characteristicproperties, such as mass, density, maximum tensile stress, maximumstrain, weight, dielectric or conduction properties, and so forth.Likewise, structural strength, coefficience of thermal expansion withtemperature, resistance to corrosion, and so forth may be selected 86 asmaterial properties that will govern construction of an anchor 10.

Selecting 87 securement systems may involve securements at oppositeextremes ends of each anchor 10. For example, a securement mechanism tosecure a base 12 to a wall 52 of a building may be one securement, whilethe securement by way of a fastener 34, keeper 32, or integrated arms 62and guides 64 may also be considered securements. Accordingly, selecting87 the types and numbers, as well as the operating mechanisms forvarious securements may determine what form of anchor 10, and whatmechanical configuration may be required.

Ultimately, selecting 88 materials for each of the components includedin an anchor 10, may result directly or indirectly the previousselections 85, 86, 87. Moreover, selecting 85, 86, 87, 88 may alsoinclude, and in an overall context will include, selecting the materialsthat will be used in the overall lightning protection system.

For example, cables may be fabricated of copper, aluminum, or othermaterials. Typically, the duty cycle, weight, electrical conductivity,thermal conductivity, and so forth do not require gold. Circuits existthat are fabricated using gold as the conducting material. Nevertheless,typically, aluminum tends to be lighter than copper, whereas coppertends to be a better conductor based on area, mass, and various otherparameters. By the same token, aluminum is considered more economical.Thus, selecting 88 a material for a cable 56, anchors 10, brackets 34,integrated anchors 70, points 40, and so forth may significantconsiderations of material properties, fabrication methods, and soforth.

Cutting 89 stock into the materials and components to be used applies toboth the components of the installation, as well as the anchors 10 andtheir associated or corresponding parts. For example, cutting the pad14, that has been selected 88, at the dimensions specified willconstitute one element. By the same token, cutting 89 anchors 10, orbase plates 12, or studs 16, or otherwise fabricating them may beanother consideration. Similarly, folding of metal sheets after cutting89 to size, and possibly cutting 89 with separation lines forappropriate folding may also be included. Likewise, methods of makingand using brackets 34 to support cables 56, points 40, or the like maybe considered.

In one embodiment, cutting 89 integrated anchors 70 may involve stampinga blank 130 (See FIGS. 42 and 46), and cutting certain separation linesin that blank 130 to be followed by other manufacturing processes.

Another manufacturing process 90 or step 90 may include assembly,fabrication, or both for an anchor. For example, in certain embodiments,the stud 16 may be formed as part and parcel of an anchor 10, as amonolithic, homogeneous, integral portion of the anchor. Thus, like anail, bolt, or the like, the anchor 10 may be formed with a base 12 andstud 16 of a single material, formed, stamped, forged, or otherwisemanufactured in a single step, or single process, as a suitablemanufacturing method.

By the same token, bases 12 and studs 16 may be cut from flat stock andround stock and welded, pressed, threaded, or otherwise fabricated tobond together. Likewise, the entire anchor 10 may be fabricated of apolymer material in a molding process or by other suitable approach.

Other components to be assembled 90, fabricated 90, or otherwisemanufactured 90 may include a nut 32 or other type of keeper 32, afastener 34, adapted to securely holding a point 40 or cable 56, or thelike.

In one fabrication 90, contemplated within the scope of the presentinvention, a flat material bender may fold past a yield point the middleof a blank 130 for an integrated anchor 70. Various bends may berequired in order to form all the distinct arms 62, guides 64, retainers66, detents 67, vertices 69, and so forth with the appropriate gaps 63,angles, clearances, or the like. Likewise, other manufacturingprocesses, such as quality control, buffing, blasting, painting, heattreating, and so forth may be important to the material propertiesselected 86. Some process steps may also be done with blanks, finishedparts 10, or the like.

Packaging 92 the individual anchors 10 or components for the anchorsystem may be adapted to the ultimate use thereof. For example, inassembling 90 an anchor 10, the pad 14 may be manufactured, provided,cut 89, and assembled 90 to go into a packaging step 92 as a systemready to be installed with virtually no tools. In other embodiments, thepads 14 may each be provided as a separate article or a supply to besecured to a base 12 of an anchor 10 at the time of installation.

Accordingly, providing 91 procedures to installers may include printedinstructions, downloadable files, website instructions, or the like. Infact, written procedures that will be packaged 92 with the anchors 10may be included, while online instructions may also be provided 91 as aback up.

Finally, distributing 93 the anchors 10 through secondary distributionchannels, direct to users, to installers, or the like may be done in asuitable manner. Typically, packaging 92 may include warnings, which mayalso be part of providing 91 procedures.

A process 84 or method 84 for installing an anchor 10 in accordance withthe invention may begin with accumulating or otherwise gatheringspecifications for the performance of a lighting-protection system.Based on distances, sizes, topography, geology, urbanization, and soforth, one may analyze 94 the specifications for a particular project.This may lead to the consequent points 40 to be supported and cables 56to be carried by the anchors 10.

Selecting 95 sizes, materials, and processes for assembling andinstalling the anchors 10 and their associated points 40 and cables 56will appropriately follow. Sizes in certain embodiments are standardizedand established by building codes. Building protection codes forarresting lightning exist in many jurisdictions, and may bedeterminative of selecting 95 the sizes, materials, and processes forinstallation. In other jurisdictions, cost, contemplated conditions, andthe like may also factor into the selection 95 of materials, theirsizes, and their processes for installation.

An installer may then apply the systems 96 by obtaining fromdistribution 93 the quantities of anchors 10, keepers 32, points 40,cables 56, other fasteners, and install them. Typically, anchors 10 willbe installed near the highest extrema of a building, thereby protectingthe building, it's metallic components, its structure, and so forth fromthe high voltages, currents, heating, and the like associated withlightning strikes.

In general, lightning protection systems will be grounded to earth.Points 40 will extend at their distal ends to increase the voltagestress or provide a stress concentration point at the distal end of apoint 40. Thereby, dielectric breakdown in the surrounding air willoccur first at a point 40, and particularly at the distal end of thepoint 40. Thus, following the initial corona effect that is typical ofelectrically active atmospheres, the electrical breakdown by lightningwill occur at the distal end of a point 40, sending electrical currentthrough the point 40, its anchor 10, and to the associated cables 56carrying current to a grounding cable 56 that eventually is anchored inthe earth.

Referring to FIG. 29, in one embodiment of a method in accordance withthe invention, an application process 100 may involve sizing 101 anchors10 for use in an installation. Therefore, selecting 102 a material forthe pad 14 may be conducted. Sizing 103 the pads 14 may includeconsideration of surrounding materials, clearances, thicknesses, areas,sealing, offsets, or the like. Thickness may be governed by structural(stress, strain) requirements, installation to tolerances, and relativecoefficients of thermal expansion of surfaces 35, bases 12, and pads 14.In certain embodiments, sizing 103 the pads may be dictated by thesizing of the base plate 12 to which each pad 14 will connect.

Cutting 104 the pads and applying 105 the pads 14 to a base plate 12 maybe done at the time of installation, or may be done in a manufacturingprocess 100 at a factory shipping completed anchors 10. Likewise,applying 105 the pad may involve cutting 104 a pad to size.Nevertheless, in some embodiments, applying 105 the pads 14 to the baseplates 12 may occur in a factory.

Installation may then include selecting 106 a location 60 on a building.Typically, the location 60 will be near the top of the building, andtherefore on a flashing 54 or cap 54 covering a parapet 52 or a wall 52.Cleaning 107 the location 60 may involve mechanical abrasion, chemicalcleaning, or simply a solvent wash. Typically, slight scrubbing with asolvent will clean off residues. In some embodiments, cleaning 107 mayinvolve removing oxidized material having poor adhesion to the surface35 of the base material at the location 60.

Exposing 108 the pad 14 may involve removing a polymeric film that haslow adhesion forces with respect to the adhesive pad 14. Thus, exposing108 the pad 14 by removing a film, for example, permits a user orinstaller to apply 109 the anchor 10 by pressing the anchor 10, and theunderlying pad 14 against the location 60 on the surface 35. In thismanner, the adhesive properties of the pad 14 may bond to the surface 35as an adhesive process.

In certain embodiments, it has been found that a pressure sensitiveadhesive operates well. Structural adhesives exist, and pressuresensitive adhesives exist. Accordingly, in one embodiment, the pad 14 isprovided with, or as part of a pressure sensitive adhesive system havingan expanded polymeric material (polymer foam) having adhesive front face22 and rear face 24. Upon application of pressure, the adhesive mayadhere, or actually cure.

That is, for example, certain acrylates require a lack of oxygen tocure. Other materials, such as epoxies and other materials may cure byheat, light, reagents, other chemicals, or the like. Accordingly, theadhesive may be applied as multi-part, single-part, heat-curable,pressure-sensitive, or otherwise. Applying 109 an anchor 10 may providesufficient strength in the bond between the pad 14 and the surface 35 toimmediately mount the remainder of the lightning-protection system.

In certain embodiments, it may be required to apply 110 a curecondition. For example, time, heat, light, chemicals, or the like may berequired to cure the adhesive of the pad 14. Accordingly, applying 110the condition required to effect a cure may require time, an additionalstep 110, or the like. In certain embodiments, applying 110 to curecondition may be simply a matter of waiting for passage of time with orwithout pressure.

Positioning 111 a cable 56 in the anchor 10, or in a position to besupported by the anchor may be followed by binding 112 the cable to theanchors 10 as discussed hereinabove. Typically, binding 112 the cable 56may involve tensioning the cables by binding 112 and end of a segment ofcable 56 at one clamp, and pulling a tensile load in the cable 56, inorder to reduce sag, before binding 112 the cable 56 at the next orcertain intermediate anchors 10.

Referring to FIGS. 30 and 31, while continuing to refer generally toFIGS. 1 through 48, a system 10 in accordance with the invention mayinclude a head 120 manufactured by any suitable method, such as casting,forging, rolling, stamping, machining, or the like. Thus, the head 120may be a forging, casting, fabrication, or the like.

In certain embodiments, it is possible that the head 120 may be stamped,but such a configuration is less desirable. One reason that a casting orforging process may be preferred is that current density should be lowand thermal mass high. Plenty of solid, conducting metal cross sectionis desired. A suitable dimension for the diameter of the head 120 isfrom about 2 to about 3 inches. Typically, 2¼ inches would provide agood target diameter for the head 120. Similarly, the thickness may befrom about ½ to about 1 inch. A target thickness of about 0.63 inches iscontemplated for one present design concept.

The head 120 is shaped something like a puck 120 in order to providesignificant mass and stiffness. The mass is effective to absorb energyor heat without the head 120 overheating, melting, or otherwisesuffering catastrophic damage during a lightning strike. Likewise, thethickness provides stiffness or an improved “section modulus” as thatterm is understood in the engineering art. A higher section modulusprovides for greater stiffness of the component 120, and thus betterclamping force without damage or distortion.

The head 120 may be provided with various apertures 122, 124, as well asexcavations 126 or relief 126 or relief channels 126 forming slots 126on the underside 128 b opposite the top face 128 a. The aperture 122 aoperates as a receiver 122 a to receive a vertically oriented point 40therein by threaded engagement, with the head 120 in a horizontalorientation. In contrast, the receiver 122 b extends through thecircumference of the head 120 in order to orient a point 40 verticallywhen the head 120 is mounted to a base plate 12 on a pad 14 against avertical surface of a building or other protected structure.

Herein, a trailing letter following a reference numeral refers to aspecific instance of the item identified by the reference numeral.Therefore, it is appropriate to refer to a receiver 122 to include anyparticular one or all receivers 122, and the receivers 122 a, 122 b asthose receivers that are specified for specific examples of structure orfunction.

A point 40 may be threaded into the appropriate receiver 122 a, 122 b.This should follow after the head 120 has been properly mounted to asurface of a protected structure.

Mounting the head 120 is accomplished by use of the apertures 124 whichserve as securement apertures 124. Meanwhile, the relief channels 126 orslots 126 are formed in the back face 128 b or back surface 128 b of thehead 120. The relief channels 126 are formed as partially excavated,machined, molded, or forged channels 126. These channels 126 or reliefchannels 126 may be shaped rectangularly, as semi circles, or as someother curved shape. The cross section of a curved shape may be fitted tothe outer circumference of a connecting cable 56 (conductor 56)connecting the head 120 and its associated point 40 to the overalllightning protection system.

By crossing each of the channels 126 or reliefs 126 at right angles toone another, the head 120 can be accessed by a cable 56 from either ahorizontal traverse (run) or from a vertical climb (run). Thus,regardless of whether a cable 56 is coming from another anchor system 10spaced horizontally away or spaced vertically away from the head 120,the cruciform orientation of the channels 126 will accommodate captureof a cable 56 therein.

In order to provide a capture of a cable 56 by the universal mount head120, a cleat plate 130 or mandible 130 sits under the cable 56 oppositethe back face 128 b of the head 120.

The cleat plate 130 or mandible 130 is provided with racks 132corresponding to each side. Each rack 132 is cut to form teeth 134 atthe extreme edge thereof. The racks 134 may be formed by cutting,stamping, or otherwise separating the rack portion 132 from the bulk ofthe mandible 130. Thus, the rack 132 may be cut along with the shape ofthe teeth 134 in a single operation.

Eventually, during cutting, or thereafter, the racks 132 may be bent toextend away from the remainder of the cleat plate 130 or mandible 130 atan angle of from about 30 to about 60 degrees. A target angle of about45 degrees has been found suitable. The teeth 134, and their racks 132,meanwhile may be formed to be from about ½ to about 1 inch wide, with atarget distance of about 0.63 inches and a clearance of an additional 2to 3 thousandths of clearance between the rack 132 and the surroundingmaterial of the mandible 130.

The racks 132 may be centered along each side of the mandible 130. Theoverall length of each rack 132, including the teeth 134 may be fromabout ⅓ to about ½ inch, with a target distance of about 0.4 inches,with an additional clearance of a few thousandths. The illustratedembodiment has about 3 thousandths clearance between the teeth 134 andthe surrounding material of the mandible 130.

In the illustrated embodiment, the apertures 136 in the mandible 130 areformed near each of the four corners, which may be rounded appropriatelyfor manufacturing and safety purposes. The apertures 136 in oneembodiment are equidistant from one another along each side such thatthe mandible 130 may be fit within a square that is thereby planarsymmetric with respect to a diagonal or median therethrough. Thus, eachcenter line provides a line of symmetry, each diagonal provides a lineof symmetry, and a point on an axis perpendicular to the plane of themandible 130 is a point of symmetry in that plane.

Thus, the apertures 136 may be sized and fitted to secure with nuts 32on the studs 16 of a base plate 12. A square base plate 12 mounted to asuitable pad 14 may mount to a building or other protected structure asdescribed hereinabove. By having point symmetry in the base plate 12,and its studs 16, the mandible 130 or cleat plate 130 may be mounted inany of four different orientations. Symmetry renders each pair of suchorientations symmetric or identical.

However, the orientation of the studs 16 may be vertical or horizontal.Meanwhile, the mandible 130 also has studs 140 that may be welded,forged, threaded, swaged, pressed, or otherwise secured to the mandible130. The studs 140 in one embodiment are called PIM studs. These studs140 have a stepped head 142 that has a spline 144 or a splined portion144 in addition to the threads 146. The head 142 is formed to besufficiently large that it will not fit through an aperture 124. Thespline 144 makes an interference fit to be swaged into securement withinthe mandible 130, thus becoming part of the mandible 130. The threads146 pass through the apertures 139.

The large contact surface area of the studs 140 against the main expanseof the mandible 130 assures that good electrical contact is made.Nevertheless, as opposed to prior art systems and brackets, the head 120renders the studs 140 of less consequence. For example, in prior artsystems, attachment hardware has often been responsible for carryingelectrical current. Small cross sectional areas, small thermal mass,weak mechanical structures, and the like have contributed to suchhardware being literally taken out of the circuit by evaporation,melting, distortion, or the like. In contrast, the contact area betweenthe relief channels 126 and the cable 56, is relied upon and isextensive.

The pressure is substantial that may be brought to bear by securing thenuts 138 onto the studs 140 to capture the head 120 against the mandible130. Specifically, the teeth 134 of the mandible 130 provide a securedconnection and a substantial load (force, pressure). The relief channelsprovide a large contact surface area. Thus, the connection between thestuds 140 and the remainder of the mandible 130 need not actually carryany electrical current. Nevertheless, the teeth 134 still provide goodcontact, and another path of electrical connection, as well as amechanical stabilization of the cable 56 within the relief channels 126.

The head 120 saddles the cable 56 or conductor 56, and the relief 126 isless than a semicircle. Thus, the head 120 may be tilted (rotated) aboutthe conductor 56 at installation. In one embodiment, sufficienttolerance may be provided between the apertures 124 and studs 140 topermit adjustment (e.g., tilting, leveling) of the head 120, to true thepoint 40 to a plumb line (vertical).

For example, in the configuration of FIG. 30, to level the head 120, thenut 138 on a stud 140 on one side of the head 120 may be threaded downfarther than the nut 138 opposite. By thus rocking or tilting the head120, about the conductor, toward that side, the head may be leveled. Thepoint may be moved with the head into a trued vertical (plumb)orientation.

In another configuration, seen in FIG. 31, the head 120 may be similarlytilted about the conductor 56 mounted on a vertical, protected surface.The point 40 may be tilted as necessary to render it plumb.

In a typical embodiment, it will be unnecessary to pivot the head 120about the center of its diameter (e.g., rotate the disk about its centerof symmetry). This is because the base 12 may be and should be oriented(rendered plumb) at the time of installation against the attachmentsurface of the protected structure.

However, in one embodiment, tolerances in the studs 16 and nuts 32, aswell as in the studs 140 and nuts 138, may be constructed to permitslight rotation of the head 120 (with respect to a vertical mountingsurface) about the center of its diameter. For example, in FIG. 31, theapertures 136 may be round, somewhat oval, or slots permitting moremovement. However, as stated hereinabove, there is a benefit tocomparatively closer tolerances precluding any “requirement” ofadjustment by rotation about that center point. Note that there may betwo or four studs 16, although only two are shown, for clarity, in FIGS.30 and 31.

Referring to FIGS. 30 through 32, a method for installation may sequencecertain assembly processes. For example, in certain embodiments, a pad24 may be applied to a building or other protected structure prior toapplication of a base plate 12. However, the base plate 12 may bemanufactured with the pad 14 secured thereto with the back face 20 ofthe base plate 12 secured to the front face 22 of the pad 14. In thisconfiguration, the back face 24 of the pad 14 may be covered with asuitable protective layer to be removed at the time of installation. Onebenefit to having the pad 14 and base plate 12 preassembled is to removeany need for alignment therebetween in the field.

Also, the studs 16 provide a mechanism for handling and manipulating thebase plate 12. They make sure it may be oriented as desired. Typically,this will mean that the base plate 12 will have one edge of one sidethat is exactly horizontal. In a vertical orientation for the surface ofa protected structure, the top edge of a base plate 12 will behorizontal, as well as the bottom edge. The base plate 12 will beorientated as a vertical plane secured to the protected structure.

In a horizontal orientation for the surface of a structure (and the hub120 or head 120), the base plate 12 is oriented as a horizontal plane.The orientation within that plane is not particularly consequentialother than orienting to receive the cable 56. Thus, the head 120 may besecured to the base plate 12 together with the mandible 130 or cleatplate 130.

In one embodiment, the base plate 12 and pad 14 arrive from the factorypreassembled for positioning on a vertical or a horizontal surface. Onsite, the base plate 12 is simply secured to the protected structure atthe proper location and the vertical or horizontal orientation desired.

Thereafter, the mandible 130 may be oriented according to the positionof the head 120 in the ultimate point 40 configuration. For example, inthe illustrated embodiment, the receivers 122 a, 122 b are drilledapertures 122 a, 122 b threaded to receive a point 40 therein. However,in any particular installation, one head 120 need receive a single point40. That point 40 will be threadedly secured into either the receiver122 a (when the head 120 is on a horizontal protected surface) or thereceiver 122 b (when the head 120 is secured to a vertical protectedsurface).

Although the apertures 124 are point symmetric and planar symmetricwithin the head 120, there is not sufficient room in the illustratedembodiment to provide multiple receivers 124 b around the circumferenceof the head 120. Thus, for example, one will note that one half of thehead 120 contains the receiver 122 a, and the other side or half of thehead 120 contains the other receiver 122 b.

Thus, although the apertures 124 may be registered on the studs 140 ofthe mandible 130 in either of two directions, 180 degrees apart, onlyone will result in the point 40 extending vertically. Thus, the mandible130 or cleat plate 130 on a vertical protected surface needs to have theorientation or relative positions of the studs 140 arranged to positionthe point 40 vertically.

It is conceivable that points 40 may be oriented horizontally in someconfiguration. However, this is typically an exception. The points 40are typically mounted on the highest location in a protected structure.That highest extremum must be accessible. The comparatively smallerdiameter to longer length (aspect ratio) of each of the points 40(compared to the protected structure) is important. A point 40 tends toproduce the electrostatic stress that will induce earliest electricalbreakdown of the atmosphere associated with a lightning struck.

Referring to FIGS. 33 through 40, while continuing to refer generally toFIGS. 1 through 48, the head 120 is designed to have a thickness anddiameter that provide the relief channels 126 sufficient contact surfacearea with a cable 56 (conductor 56) secured thereby. Meanwhile, theteeth 134 of the racks 132 urge the cable 56 into contact with therelief channels 126. Racks 132 may be deflected, deformed, or otherwisemoved elastically, plastically, or both by the force of the head 120thereagainst when cinched down by the head 120 in response to the nuts138 on the studs 140.

One will note that the receiver 122 a may conveniently be formed as athrough-hole 122 a through the entire thickness of the head 120. Incontrast, there is little or no benefit to making the receiver 122 b asa through-hole configuration. In some embodiments, relief may berequired in the receiver 122 b in order to accommodate threading thereinto by the point 40.

The holes 124 or apertures 124 may be sized to fit snugly, or to providesufficient clearance for easy assembly. In one embodiment, the apertures124 are nominally at about ⅜ of an inch, but may range from about ¼ toabout ⅜ of an inch. At around ½ inch, interference with the cable 56 maybe a problem since the cable 56 must traverse across opposite racks 132of teeth 134 between the studs 140.

The studs 140 are positioned such that the cable 56 may cross themandible 130 across either opposing pair of racks 132 and associatedteeth 134. Thus, the mandible 130 with its orientation is not dependenton the orientation of the cable 56. It can accommodate either verticalor horizontal cables 56. However, the position of the studs 140 doescontrol the orientation up or down by the point 40 if threaded into theedge receiver 122 b (compared with the face receiver 122 a).

Referring to FIGS. 35 through 40, one may see that the apertures 124 arejuxtaposed to one another on opposite sides of the cable 56. The cable56 may pass therethrough in either orthogonal (horizontal or vertical,or lateral or transverse) direction. Likewise, each of the receivers 122a, 122 b is drilled at a location such that it will not interfere witheither of the apertures 124. Thus, each quadrant of the head 120 definedby the cruciform of the relief channels 126 is occupied by either areceiver 122 a, 122 b or an aperture 124 for receiving a stud 140.

Typically, the relief channels 126 are conformal to the diameter of acable 56. However, a nominal ½ inch diameter may be from about ⅜ toabout ¾ of an inch. Typically a target diameter is about 0.56 inches.Nevertheless, the incursion of the relief channel 126 is not the fulldiameter thereof. Rather, a distance of from about 1/10 to about ¼ inchwith a target distance of about 0.13 inches has been found suitable forincursion of the arc of the relief channels 126 into the head 120.

Referring to FIGS. 41 through 48, a cleat plate 130 or mandible 130 maybe formed from a blank 130 stamping. The completed mandible 130 or cleatplate 130 with associated racks 132 of teeth 134 and studs 140 in placefor installation is illustrated in FIGS. 41 through 45. The blank 130 isillustrated in FIGS. 46 through 48.

At installation, the racks 132 extend at an angle of about 45 degreesfrom the main portion of the cleat plate 130 or mandible 130 in theillustrated embodiment. The studs 140 may extend a distance suitable forreceiving a nut 138 and the head 120 with ample length to spare. Thus,the studs 140 may extend from about ¾ to about 1¼ inches. The apertures136 of the mandible 130 are difficult to impossible to access under thehead 120. At the least, the access to the nuts 32 securing the mandible130 to the base plate 112 are most easily secured before attachment ofthe head 120 to the studs 140 by the nuts 138.

Referring to FIGS. 41 through 45, the bending of the racks 132 providesa certain amount of clearance gap between the racks 132 and the adjacentbase material of the cleat plate 130 or mandible 130. However, in theoriginal blank 130, a minimal clearance exists between the racks 132 andthe base material of the mandible 130 or cleat plate 130.

Referring to FIG. 44, the studs 140 are shown as installed, a cut awayview illustrating the underlying shape of the head 120 with a spline 144for securement by swaging into the mandible 130 or cleat plate 130.

Referring to FIGS. 46 through 48, one will note that the blank 130configuration has no studs 140 installed, and the racks 132 are coplanarwith the remainder of the mandible 130. In some embodiments, the blank130 may be cut as a flat member as illustrated. However, in certainembodiments of a process for manufacturing the mandible 130, thestamping of the mandible 40 may include cutting and bending of the racks132 to their final orientation. However, insertion of the studs 140 willnecessarily require a previous drilling operation or stamping operationto create the apertures 139 for receiving the studs 140.

Referring to FIGS. 47 and 48, one may see that the blank 130 of a cleatplate 130 or mandible plate 130 is basically a single rectangle ofstandard sheet stock. Only the racks 132 with their teeth 134 along withthe studs 140 extend above that planar surface.

Referring to FIG. 48, in certain embodiments, the racks 132 may beformed (yielded) into their alternate positions prior to installation ofthe studs 140. In certain embodiments, the stamping of the shapes of theracks 132 and teeth 134 may be done in a single stamping operation. Infact, the apertures 136, 139 may actually be formed in the same stampingoperation as the formation of the racks 132 and teeth 134.

Punching, cutting, and bending may all be done in a single operation. Inother embodiments of a process for manufacturing, the apertures 136, 139may be drilled, and the bending of the racks 132 into position may occuras a separate operation. This is a matter of manufacturing economy as towhich sequence of events would be followed. Thus, the blank 130 may beready to receive both the bending of the racks 132 and the insertion orswaging of the studs 140 into position.

Alternatively, the embodiment of FIG. 48 may be an intermediateconfiguration of a blank mandible 130. It may result following stampingor drilling of any cuts or apertures needed. It may also follow bendingof the racks 132, but come before swaging of the studs 140 intoposition.

A threaded receiver 122 a provided in the head 120 or hub 120 formounting an “air terminal” point 40 should typically have at least fivefull threads. If internally threaded the minimal wall thickness shouldbe not less than 1/16 inch (1.6 millimeters) at the base of the threads.Each base plate 12, and cleat plate 130 or mandible 130 should haveconnector fittings suitable for supporting the forces imposed by theweight of the lightning conductor 56 or cable 56, as well as the system10.

The conducting cross sectional area between the cable 56 and the reliefchannels 126 of the head 120 or hub 120 should be equal to or greaterthan the cross-sectional area of the conductor 56 (cable 56). Thecontact between the cable 56 or conductor 56 and the relief channels 126in the underside of the head 120 should be not less than 1½ inches (38millimeters) on opposite sides of the cable 56 and comply with IEEEstandard 837 for commercially available lightning protection conductors.

The mounting apertures 136, as well as the apertures 139 for the studs140 should accept a number 10-24 or larger bolt or screw required topermanently and rigidly secure the head 120 or hub 120 to the mandible130 or cleat plate 130. In certain embodiments, the adhesive base pad 14will include a minimum footprint of about 7 square inches (45.16 squarecentimeters) overall. Meanwhile, the cleat plate 130 or mandible 130includes six openings of about ¼ inch (6.35 millimeters) or greater andan overall minimal width of about 2 inches (50.8 millimeters).

The typical materials may be aluminum of thickness of three thirtyseconds of an inch (2.4 millimeters) minimum in a casting or 0.97 inches(2.46 millimeters) in a stamping. Likewise, a copper or copper alloymandible 130 may include a minimum thickness of three thirty seconds(2.4 millimeters) if cast, and 0.061 inches (1.55 millimeters) ifstamped.

Materials may be alloyed, but should be electrical grade implying thatthey meet the minimal electrical conductivity standards for UnderwritersLaboratories standard 96 which is the standard for lightning protectioncomponent sections. Chamfers and radii break all sharp corners.

The present invention may be embodied in other specific forms withoutdeparting from its purposes, functions, structures, or operationalcharacteristics. The described embodiments are to be considered in allrespects only as illustrative, and not restrictive. The scope of theinvention is, therefore, indicated by the appended claims, rather thanby the foregoing description. All changes which come within the meaningand range of equivalency of the claims are to be embraced within theirscope.

What is claimed and desired to be secured by United States LettersPatent is:
 1. An apparatus orienting arbitrarily a point of a lightningprotection system, the apparatus comprising: a head having an outersurface defining a perimeter and characterized by an effective diameterextending across the outer surface; the head, having an inner surfacedefining a thickness extending between the inner and outer surfaces; thehead, having a perimeter surface characterized by the perimeter andthickness; the head, further provided with a first penetration throughthe outer surface and a second penetration through the perimetersurface, each sized and configured to receive and secure the point; amount securable to a mounting surface of a protected structure andhaving a mount orientation defined arbitrarily between vertical andhorizontal by the mounting surface; and a mandible comprising aconnector securing the head thereto in any selected position of aplurality of positions effective to orient the point verticallyindependently from the mount orientation and absent any substantialdistortion of the head.
 2. The apparatus of claim 1, wherein: the headis maintained in contact over a contact area with a conductor by a forcebetween the had and the mandible; and the head provides across-sectional area for conduction between the point and the conductorgreater than the contact area.
 3. The apparatus of claim 2, wherein thedirect conductive path between the point and the conductor passes onlythrough the head.
 4. The apparatus of claim 3, wherein: the apparatusdefines a conductor contact envelope bounded by the conductor and thehead and a point contact envelope bounded by the point and the head; andthe conductor and the point are sufficiently close to the head toconduct by arc within the conductor contact envelope and point contactenvelope in the event of a lightning strike on the point.
 5. Theapparatus of claim 4, wherein the conductor contact envelope is selectedto be in the conductive path of a lightning strike to the substantialexclusion of the mount.
 6. The apparatus of claim 4 wherein theconductor contact envelope is sized and shaped to be in the conductivepath of a lightning strike to the substantial exclusion of the mandible.7. The apparatus of claim 4, wherein: the mount comprises mount studsextending away from the mounting surface; the mandible is provided withapertures sized and positioned to fit over the mount studs in any of aplurality of mandible positions; and the mandible further comprisesmandible studs extending away from the mounting surface and presentingat least two configurations of the mandible studs; and the head isprovided with apertures arranged to orient the head based on the atleast two configurations of the mandible studs.
 8. The apparatus ofclaim 7, wherein: the mount and the mandible are outside the most directcurrent path between the point and the conductor.
 9. The apparatus ofclaim 1, wherein: the conductor is connected to a ground; the mount andthe mandible are outside the direct current path between a lightningstrike striking the point and the ground.
 10. The apparatus of claim 1,further comprising: a second mount; a second head; a second mandiblesecuring the second head to the second mount; the conductor, routed topass between the second head and the second mandible; and a groundoperably connected to an end of the conductor distant from the point.11. An apparatus comprising: a mount; a point configured to receive alightning strike; a head shaped to connect to the mount, to secure thepoint, and to receive a conductor, the head serving as the direct pathof the lightning strike from the point to the conductor; the conductorshaped to contact the head between the head and the mount through aconductor contact area; the head and conductor mutually shaped to sharea point contact area therebetween; and wherein the cross sectional areaof the head between the point and the conductor is at least as great asthe greater of the conductor contact area and the point contact area atall locations therebetween.
 12. The apparatus of claim 11, furthercomprising; a mandible connected intermediate the head and the mount tosecure the conductor in contact against the head.
 13. The apparatus ofclaim 12, wherein the mandible further comprises: teeth sized and shapedto engage the conductor in fixed relation thereto.
 14. The apparatus ofclaim 13, wherein the mandible further comprises: mandible studsextending to receive the head; and the mandible studs are positioned toreceive the head in multiple positions.
 15. The apparatus of claim 14,wherein: the mount is provided with studs positioned to receive themandible in any of a plurality of orientations.
 16. The apparatus ofclaim 15, wherein: the mandible is further provided with aperturespositioned to receive the studs; and the mandible studs are positionableabsent yielding of any of the mount, the mandible, and the head byselection of a selected orientation of the plurality of orientations.17. The apparatus of claim 12, wherein the mount and the mandible areoutside the direct path of the lightning strike through the point to theconductor.
 18. A method for mounting a point for arresting lightning,the method comprising: selecting a conductor comprising a cable made ofa first material; selecting an anchor securable to a protectedstructure; providing a mandible positionable on the anchor in any of aplurality of positions; selecting a relative orientation for the pointwith respect to the anchor; positioning the mandible, based on therelative orientation; providing a head adapted to secure to themandible; selecting an aperture in the head, based on the relativeorientation, and positioning the point in the head, based on therelative orientation and without yielding the head.
 19. The method ofclaim 18, further comprising the positioning the point absent yieldingthe mount.
 20. The method of claim 19, further comprising thepositioning the point absent yielding the mandible.